Research And Application Of Aluminum Alloy Semi-continuous Casting Process Control System

With the wide application of aluminium alloys in aerospace,transportation,automobile manufacturing,machinery manufacturing,shipbuilding and chemical industry,higher requirements have been put forward in terms of toughness,precision and corrosion resistance.Casting of aluminium alloy round ingot is the first step in the manufacturing process of aluminium alloy products.The quality of ingot directly determines the properties of aluminium alloy products.Alum-inum alloy semi-continuous casting machine is the main equipment for producing aluminium alloy round ingots.The stability of the casting machine and the control of casting parameters determine the quality of aluminium alloy round ingots.The stability of aluminium alloy casting control system directly determines the safety of casting process control,the quality of round ingot and production efficiency.Therefore,it is of great engineering significance to study the process control system and intelligent optimization control of controlled parameters for semi-continuous casting of aluminium alloy.At present,in the process of semi-continuous casting of aluminium alloy,the traditional closed-loop PID control is often used to control the process control parameters.However,due to the complex industrial site and large external di-sturbances,the control system is unstable,the error of controlled parameters is large,and the control effect is poor,which ultimately affects the quality of round ingot.Aiming at the above problems,the method based on fuzzy neural network control is used to optimize the casting speed and water quantity,which makes the control error smaller and the control precision higher,and finally achieves the optimal control of casting speed and water quantity.By analyzing the technological process of semi-continuous casting of aluminium alloy in this,the working mechanism of aluminium alloy casting machine,the factors affecting the casting of aluminium alloy and the problems existing in the industrial production process of aluminium alloy casting control system,the control structure and control optimization scheme of aluminium alloy casting machine control system are put forward.Based on the process mechanism and control principle,the overalldesign scheme of the control system,the simulation and implementation process of intelligent control algorithm,the hardware and software design of the control system,the design of WinCC monitoring system and the network communication technology of the system are studied and discussed.The hardware of the control system includes Siemens PLC and its extension module,industrial computer,detection equipment such as pulse flowmeter,temperature sensor,liquid level meter,pressure sensor,etc.The transmission equipment includes oil pump,motor,regulating valve,etc.The software design of the control system uses SIMATIC WinCC monitoring configuration software to complete the monitoring and management of the control system,so as to realize the monitoring of the aluminum alloy casting process.The control system designed in this paper has been put into use in an aluminium factory in Yunnan.From the operation of the field control system,the control system can meet the production requirements of the enterprise.The combination of fuzzy neural network and PID control algorithm can improve the control precision and reduce the error of the controlled parameters,make the controlled parameters reach the optimal given value,enhance the anti-interference ability of the control system of the semi-continuous casting machine of aluminum alloy in the complex industrial production environment,and improve the working life of the semi-continuous casting machine of aluminum alloy.The stability in the process makes the whole casting production process proceed safely and orderly.The fuzzy neural network control algorithm solves the shortcomings of single closed-loop PID control in the casting control system,such as low control accuracy,poor stability and weak adaptability to the harsh environment.It achieves the best given casting speed and casting water quantity of the casting machine,and improves the quality of aluminum alloy ingot products.Production efficiency,has a certain significance of engineering practical application value.